Positive electrode films for alkali metal polymer batteries and method for making same

A process for extruding a positive electrode sheet having at least 40% /wt of solid content for an alkali metal polymer battery through a single or twin screw extruder, said process comprising:

• a) introducing a polyethylene oxide in a first feed throat of the extruder;
• b) introducing downstream from said first feed throat, a mixture of active cathodic intercalation material, lithium salt and carbon and graphite as electronic conductive materials, said mixture being introduced in a quantity sufficient to be at least 40% /wt of the positive electrode sheet to be produced;
• c) mixing said polyethylene oxide with said mixture introduced in b) into a single or twin screw section of said extruder;
• d) extruding a positive electrode material obtained in c) through a die opening in the form of a thin sheet;
• and
• e) depositing said positive electrode material onto a substrate.

An electrochemical cell comprising a lithium or lithium alloy based negative electrode, a solid polymer electrolyte separator and a positive electrode film, said positive electrode thin film comprising:

• a polyether electrolyte material;
• an active cathodic intercalation material;
• a lithium salt;
• and
• carbon and graphite as electronically conductive materials in a ratio of carbon/graphite ranging from about 0.5:1 to 2:1;
• wherein said positive electrode film comprises at least 40% /wt of said active cathodic intercalation material;
• lithium salt;
• and Carbon and Graphite.

A process for extruding a positive electrode sheet having at least 40% /wt of solid content through a single or twin screw extruder, said process comprising:

• a) mixing a polymer binder, an active cathode material, and an electronic conductive material into a single or twin screw section of said extruder;
• b) extruding a positive electrode material through a die opening in the form of a sheet;
• c) feeding said positive electrode material directly between a pair of rollers and without a substrate;
• and
• d) depositing said positive electrode material onto a substrate traveling near said rollers.